2004 STARTING & CHARGING SYSTEMS Starters - Excursion & F250-F550 Super Duty Pickups Diesel
2004 STARTING & CHARGING SYSTEMS
Starters - Excursion & F250-F550 Super Duty Pickups Diesel
DESCRIPTION
CAUTION: When battery is disconnected, vehicle computer and memory systems
may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.
The starter motor is a permanent magnet, gear reduction, 12-volt DC motor, equipped with an integral solenoid. Starting system consists of a starter motor, solenoid, battery, ignition switch, Digital Transmission Range (DTR) sensor (A/T), Clutch Pedal Position (CPP) switch (M/T), starter motor relay, and interconnecting cables and wires.
COMPONENT LOCATIONS COMPONENT LOCATIONS Component Location Central Junction Box Under Left Side Of Instrument Panel Clutch Pedal Position On Clutch Pedal Bracket Digital Transmission Range Sensor Inside Transmission Inertia Fuel Shutoff Switch Behind Passenger's Side Kick Panel Starter Motor Relay In Central Junction Box
ADJUSTMENTS DIGITAL TRANSMISSION RANGE SENSOR
Digital Transmission Range (DTR) sensor is mounted inside transmission and is not adjustable.
TROUBLE SHOOTING Verify customer compliant by operating starting system. Check battery for state of charge. Check cable connections at battery and starter motor. Ensure transmission is fully engaged in Park or Neutral (A/T). Ensure clutch pedal is pressed down completely (M/T). On all models, check fuse No. 31 (15-amp) and fuse No. 113 (30-amp) in central junction box. See Fig. 1. If problem is found, repair as necessary. If problem is not found, repair by symptom. See SYMPTOM INDEX table under SYSTEM TESTS.
Fig. 1: Identifying Central Junction Box Components
Courtesy of FORD MOTOR CO.
SYSTEM TESTS
CAUTION: When battery is disconnected, vehicle computer and memory systems
may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.
CAUTION: Before testing starter, ensure transmission is in Park or Neutral.
Engine Does Not Crank & Relay Clicks A Engine Does Not Crank & Relay Does Not Click B Engine Cranks Slowly C Unusual Starter Noise D Starter Spins But Does Not Crank Engine E
TEST A: ENGINE DOES NOT CRANK & RELAY CLICKS
1. Check The Voltage To The Starter Relay
Measure the voltage between the starter relay connector terminal No. 30 (Red wire) and ground. See Fig. 2. Is the voltage greater than 12.5 volts? If yes, go to next step. If no, check fuse No. 113 (30-amp). If fuse is okay, repair central junction box between fuse No. 113 and starter relay for an open. See WIRING DIAGRAMS. Test the system for normal operation.
2. Check The Voltage To The Starter Motor Solenoid
Measure the voltage between the starter motor solenoid positive terminal "B" and ground. See Fig. 3. Is the voltage 12.5 volts or greater? If yes, go to next step. If no, repair Red wire between battery and starter for an open. See WIRING DIAGRAMS. Test the system for normal operation.
3. Manually Jump The Starter Motor
Connect one end of a fused jumper wire (15A) to the positive terminal of the battery and touch the other end to the starter solenoid "S" terminal. See Fig. 3. Does the starter solenoid engage? If yes, go to next step. If no, install a new starter. See STARTER MOTOR under REMOVAL & INSTALLATION. Test the system for normal operation.
4. Test The Starter Relay
Perform the relay component test on the starter relay. See STARTER RELAY under COMPONENT TESTS. Does the starter relay test good? If yes, repair Yellow/Light Blue wire between starter relay and starter solenoid for an open. See WIRING DIAGRAMS. Test the system for normal operation. If no, install a new starter relay. Test the system for normal operation.
TEST B: ENGINE DOES NOT CRANK & RELAY DOES NOT CLICK
1. Check Starter Motor Relay Coil For Voltage
Disconnect starter motor relay. Turn ignition switch to START position. Measure the voltage between the starter motor relay connector terminal No. 86 (White/Pink wire for A/T, Tan/Red wire for M/T) and ground while holding the ignition switch in the START position. See Fig. 2. Is the voltage greater than 10 volts? If yes, go to step 7. If no, for A/T, go to step 4. For M/T, go to next step.
2. Check White/Pink Wire For Voltage At The Clutch Switch Or Jumper
Turn ignition off. Disconnect clutch pedal switch connector. Turn ignition switch to START position. Measure the voltage between the clutch pedal switch connector terminal No. 1 (White/Pink wire) and ground while holding the switch in the START position. See Fig. 4. Is the voltage greater than 10 volts? If yes, go to next step. If no, go to step 4.
Turn ignition off. Measure the resistance between the clutch pedal switch connector terminal No. 2 (Tan/Red wire) and the starter motor relay connector terminal No. 86. See Fig. 2 and Fig. 4 . Is the resistance less than 5 ohms? If yes, install a new clutch pedal switch. See CLUTCH PEDAL POSITION (CPP) SWITCH under REMOVAL & INSTALLATION. Test the system for normal operation. If no, repair Tan/Red wire between clutch pedal switch and starter motor relay. See WIRING DIAGRAMS. Test the system for normal operation.
4. Check For Voltage At Fuse No. 31
Turn ignition off. Disconnect fuse No. 31. See Fig. 1. Turn ignition to START position. Measure the voltage between the central junction box fuse No. 31 (15-amp) (Dark Green wire) and ground while holding the ignition switch in the START position. Is the voltage greater than 10 volts? If yes, repair White/Pink wire between fuse No. 31 and starter relay. See WIRING DIAGRAMS. Test the system for normal operation. If no, go to next step.
5. Check Light Green/Violet Wire For Voltage
Turn ignition off. Disconnect ignition switch connector. Measure the voltage between the ignition switch connector terminal B4 (Light Green/Violet wire) and ground. See Fig. 5. Is the voltage greater than 10 volts? If yes, go to next step. If no, check fuse No. 116 (30-amp) in central junction box. See Fig. 1. If fuse is okay, repair Light Green/Violet wire between fuse No. 116 and ignition switch. See WIRING DIAGRAMS. Test the system for normal operation.
6. Check The Ignition Switch
Perform the ignition switch component test. See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT. Does the ignition switch test good? If yes, repair Dark Green wire between ignition switch and fuse No. 31. Test the system for normal operation. If no, install a new ignition switch. See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT. Test the system for normal operation.
7. Check Relay Ground Circuit For An Open
Measure the voltage between the starter motor relay connector terminal No. 85 (Black wire for M/T, Brown/Pink wire for A/T) and terminal No. 86 (Tan/Red wire for M/T, White/Pink wire for A/T) with the ignition switch in the START position. See Fig. 2. Is the voltage greater than 10 volts? If yes, install a new starter motor relay. Test the system for normal operation. If no, for M/T, repair Black wire between starter relay and ground. See WIRING DIAGRAMS. Test the system for normal operation. For A/T, go to next step.
8. Check Brown/Pink Wire
Turn ignition off. Disconnect PCM connector C1381a. Measure the resistance between the starter motor relay socket connector terminal No. 85 (Brown/Pink wire) and the PCM connector C1381a terminal No. 4. See Fig. 2 and Fig. 6 . Is the resistance less than 5 ohms? If yes, install a new PCM. Test the system for normal operation. If no, repair Brown/Pink wire between starter relay and PCM. See WIRING
Turn ignition switch to LOCK position. Check voltage between starter motor solenoid positive terminal "B" and ground. See Fig. 3. If battery voltage is present, go to next step. If battery voltage is not present, clean and tighten connections. If battery voltage is still not present, repair or replace positive battery cable. Check system operation.
2. Check Motor Ground Circuit
Perform starter ground circuit test. See STARTER GROUND CIRCUIT TEST under ON-VEHICLE TESTING. If ground is okay, replace starter motor. See STARTER MOTOR under REMOVAL & INSTALLATION. Check system operation. If ground is not okay, repair ground circuit as necessary. Check system operation.
TEST D: UNUSUAL STARTER NOISE
1. Check The Starter Motor Mounting
Verify starter is installed properly. Check starter mounting brackets for cracks. Ensure starter bolts are tight. Repair or replace as necessary. Check system for normal operation. If noise is still present, go to next step.
Remove starter motor. See STARTER MOTOR under REMOVAL & INSTALLATION. Inspect starter motor and flywheel ring gear for wear or damage. If ring gear is worn or damaged, replace ring gear and inspect starter drive gear. If drive gear is also damaged, replace starter motor. If ring gear and starter motor are okay, perform STARTER NO-LOAD TEST under BENCH TESTING.
TEST E: STARTER SPINS BUT ENGINE DOES NOT CRANK
1. Check The Flywheel
Remove starter motor. See STARTER MOTOR under REMOVAL & INSTALLATION. Inspect flywheel and drive pinion for wear or damage. If flywheel or drive pinion is worn or damaged, replace starter motor and flywheel. Check system operation. If flywheel and drive pinion are not worn or damaged, replace starter motor.
COMPONENT TESTS
CAUTION: When battery is disconnected, vehicle computer and memory systems
may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.
NOTE: Make all DVOM connections at component terminal rather than at cable or wire end.
STARTER DRIVE TEST
1. Remove starter motor. See STARTER MOTOR under REMOVAL & INSTALLATION. Secure motor in vise. Using fully charged battery, connect negative battery terminal to starter motor case. Momentarily connect positive battery terminal to "S" terminal. See Fig. 3. Verify starter drive ejects. Remove positive lead from starter motor. Starter drive should return to original position. If starter drive does not eject and return to original position, install new starter motor. 2. Check starter drive. It should turn freely in one direction, and positively engage to armature when rotated in opposite direction. If starter drive does not move as specified, replace starter motor.
STARTER NO-LOAD TEST
1. Remove starter motor. See STARTER MOTOR under REMOVAL & INSTALLATION. Place starter motor securely in a vise. Connect remote starter switch between positive battery terminal and starter motor "S" terminal. Connect starter motor "B" terminal to positive battery post. See Fig. 3. Connect Alternator, Regulator, Battery and Starter Tester (ARBST), or equivalent, according to tool manufacturers instructions. 2. Ensure starter motor is grounded. Engage remote starter switch. Starter should eject starter drive and turn smoothly and quietly. DVOM should indicate 11 volts or more. Amperage draw should no more than 170
amps. See STARTER MOTOR SPECIFICATIONS. If voltage is lower or current is higher than specification, or unusual noise is present, install new starter motor.
STARTER RELAY
1. Remove relay from relay box. Check relay continuity. Continuity should exist between relay terminals No. 85 and 86, and between relay terminals No. 30 and 87a. See Fig. 2. Continuity should not exist between relay terminals No. 30 and 87. If continuity is as specified, go to next step. If continuity is not as specified, replace relay. 2. Using a jumper wire, apply battery voltage to relay terminal No. 85. Using a second jumper wire, ground relay terminal No. 86. Continuity should now exist between relay terminals No. 30 and 87. If continuity is not as specified, replace relay. If continuity is as specified, relay is okay at this time.
STARTER SOLENOID
Measure resistance of starter solenoid between terminal "S" and solenoid case. See Fig. 3. If resistance is not about .95 ohm, replace starter solenoid.
ON-VEHICLE TESTING
CAUTION: When battery is disconnected, vehicle computer and memory systems
may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. Before testing starter, ensure transmission is in Park or Neutral.
VOLTAGE DROP TEST
NOTE: Make all DVOM connections at component terminal rather than at cable or wire end.
1. Ensure battery is fully charged. On gasoline models disconnect ignition coil connector from ignition coil. On diesel engines, disconnect inertia fuel shutoff switch connector. On all models, connect remote starter switch between starter solenoid terminal "S" and positive battery post. Connect positive DVOM lead to positive battery post, and negative lead to solenoid terminal "M". See Fig. 7. 2. Engage remote starter switch. If DVOM indicates more than .5 volt, go to next step. If DVOM indicates .5 volt or less, go to STARTER GROUND CIRCUIT TEST. 3. Move negative DVOM lead to solenoid terminal "B". Engage remote starter switch. If DVOM indicates less than .5 volt, solenoid connections or contacts are bad. Clean solenoid terminals "B", "S" and "M". Repeat steps 1-3 , then go to next step. 4. If DVOM still indicates more than .5 volt at terminal "M" and less than .5 volt at terminal "B", solenoid contacts are bad. Replace starter motor. See STARTER MOTOR under REMOVAL & INSTALLATION. If DVOM indicates more than .5 volt at terminal "B", clean cables and connections at solenoid. Go to next step. 5. If DVOM still indicates more than .5 volt at terminal "B", check for poor positive battery cable
NOTE: Make all DVOM connections at component terminal rather than at cable or wire end.
1. On gasoline engines disconnect ignition coil connector from ignition coil. On diesel engines, disconnect inertia fuel shutoff switch connector. On all models, connect remote starter switch between starter solenoid terminal "S" and positive battery post. Connect positive DVOM lead to starter housing and negative lead to negative battery post. See Fig. 8.
2. Engage remote starter switch while observing DVOM. DVOM should indicate .2 volt or less. If DVOM indicates more than .2 volt, clean negative cable connections at battery and chassis. Also clean engine ground cable connections at front cover and engine mount bracket. 3. If voltage drop is still excessive, repair or replace negative battery cable and/or engine ground cable as necessary. Repeat starter ground circuit test after repair to ensure problem has been corrected. 4. If battery and cables test okay and starter motor still cranks slowly or not at all, replace starter motor. See STARTER MOTOR under REMOVAL & INSTALLATION.
Fig. 8: Testing Starter Ground Circuit
Courtesy of FORD MOTOR CO.
STARTER CURRENT DRAW TEST
Ensure battery is fully charged. Set parking brake and place transmission in neutral. Ensure battery connections are clean and tight. Remove fuse No. 40 in central junction box. See Fig. 1. Clamp inductive ammeter lead around all positive battery cables leading to starter. Crank engine for about 5 seconds and check amperage reading while cranking. See STARTER MOTOR SPECIFICATIONS. If amperage draw exceeds specification, replace starter.
1. Disconnect batter ground cable. Disconnect CPP switch electrical connector. Pull down on CPP switch retaining clip and slide CPP switch toward driver seat. Remove plastic retainer on top of CPP switch by pushing locking tabs together and sliding retainer forward. Remove CPP switch from clutch pedal rod and remove CPP switch. To install, reverse removal procedure.
STARTER MOTOR
Removal & Installation
Disconnect negative battery cable. Raise and support vehicle. Remove starter solenoid terminal cover. Disconnect starter solenoid wire connections. Remove starter motor mounting bolts. Remove starter motor. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
OVERHAUL Use illustration for exploded view of starter motor assembly. See Fig. 9.
STARTER MOTOR SPECIFICATIONS Application Specification Normal Cranking Speed 185 RPM Current Draw Normal Load 365 Amps No Load 155 Amps Maximum Load 1300 Amps Starter Circuit Voltage Drop (MAX) .5 Volt
